Note: Descriptions are shown in the official language in which they were submitted.
HEAT EXCHANGER ELEMENT AND METHOD FOR THE PRODUCTION
FIELD OF THE INVENTION
The present invention refers to heat exchanger elements. Furthermore, the
invention
discloses a method for the production of heat exchanger elements. Finally, the
invention
refers to a heat exchanger including inventive heat exchanger elements.
BACKGROUND OF THE INVENTION
It is state of the art to use different kinds of heat exchangers for different
purposes.
Usually, heat exchangers are used to recover heat energy from one fluid or
medium into
another one. This kind of heat energy is called sensible energy. The heat
energy or
sensible energy of one fluid, normally air, is recovered into another one
which is running
adjacent, e.g. parallel, counter or cross flow, to the first where the fluid
is at lower
temperature. By inversing fluid flows, the exchange between the two will
generate a
cooler fluid. Heat exchangers used for sensible energy recovery are usually
made of
metal or plastic plates. There are different types as there can be cross flow,
parallel flow
or counter flow configurations. The plates are defining flow channels between
themselves
so that the fluids can flow between the plates. Such devices are e. g. used in
residential
and commercial ventilation (HRV).
Another type of energy exchangers refers to the so called latent energy which
is the
moisture. To exchange the latent energy it is known to use desiccant coated
metal or
plastic substrates or membranes made from desiccant impregnated cellulose or
polymer.
Between plates made from cellulose or polymer, air passages are defined or
created to
allow the fluids to pass along the surface of the plates, thereby transferring
moisture from
one fluid to the other one. As the membranes usually have no structural
strength, it is
known to combine the membranes with frames or grids which thereby define
spacings
between the membranes.
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In case of a combination of the above, the energy exchangers are called
Enthalpy
exchanger. Those Enthalpy exchangers allow for the exchange of sensible and
latent
energy, resulting in Total Energy recovery.
Membrane materials as currently available are delivered by the roll. The
membrane
material is the most critical part of an Enthalpy exchanger. The membrane must
be fixed
and sealed to a kind of grid or frame and arranged in a way to allow for a
fluid to flow
between each membrane layer. So, it is obvious that Enthalpy exchangers of the
known
art are a compromise. They will usually lose in sensible energy to gain in
latent energy as
a result of the selective scope and characteristics of currently used
membranes.
Such a heat exchanger built from respective elements is e. g. WO 02/072242 Al.
On
grids respective membranes made of fibres are positioned. The grids are
stapled thereby
altering the direction of the plates in order to create different air flow
directions.
In view of the mentioned state of the art it is an object of the invention to
provide heat
exchanger elements and heat exchangers as well as a method for the production
of heat
exchanger elements. The inventive heat exchanger elements allows for the
creation of
Enthalpy exchangers whereby the efficiency of sensible energy exchange and
latent
energy exchange can be varied and controlled and especially improved.
SUMMARY OF THE INVENTION
With the invention, the solution of the above mentioned object is presented by
a method
for the production of heat exchanger elements comprising the steps of:
a) producing a plate element with defined outer dimensions and corrugations in
the area within a border;
b) perforating the plate in predefined areas and in predefined dimensions;
c) filling the perforations with a polymer with latent energy recovery
capability; and
d) curing the polymer.
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With regard to the heat exchanger element, the object is solved by a heat
exchanger
element including a plate element with defined outer dimensions and
corrugations in the
area within a border, said plate element has perforations in predefined areas
and in
predefined dimensions, wherein said perforations are filled with a polymer
with latent
energy recovery capability.
The invention also concerns a heat exchanger with at least three plates like
heat
exchanger elements fixed to each other in parallel orientation to form two
fluid paths
allowing fluids to flow there through, wherein the plate like heat exchanger
elements are
heat exchanger elements as defined herein.
The invention is also directed to a method for the production of heat
exchanger elements
of a type for use in a residential or commercial total energy exchanger
comprising:
a) producing a plate element with defined outer dimensions and corrugations in
the area within a border, wherein the plate element is made from a material
having
sensible energy recovery capability;
b) perforating the plate in predefined areas and in predefined dimensions,
wherein
said perforated area provides a plurality of holes allowing the water vapor to
migrate from one side of the plate material to the other side;
C) filling the perforations with a polymer with latent energy recovery
capability, the
filling being performed while the polymer is in a dissolved state, the polymer
being
selected to provide latent energy recovery of a residential or commercial
space
during a ventilation process where stale exhaust air and incoming fresh air
travel;
and
d) curing the polymer onto the plate for forming a polymer layer within the
perforations;
wherein the polymer is a sulfonated block copolymer and the heat exchanger
element is configured for placement in a total energy recovery ventilator
(ERV),
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whereby the heat exchanger element exchanges heat as well as moisture with
respect to air that flows in contact with the heat exchanger element.
The invention is also directed to a heat exchanger element comprising a plate
element
with defined outer dimensions and corrugations to increase the exchange
surface in the
area within a border, said border being defined by a peripheral rim that
extends
completely around the area containing the corrugations, the peripheral rim
including a
first portion that is open along a corresponding edge of the plate and defines
one of an
inlet and an outlet of a flow channel, the first portion lying in a different
plane relative to
adjacent portions of the peripheral rim so as to represent a locally deformed
area of the
peripheral rim, said inlet or outlet of the flow channel being spaced from the
corrugations
and is therefore only defined by a non-corrugated portion of the plate, the
plate element
being further defined by a first face and a second face, said plate element
being made
from a material having sensible energy recovery capability, and said plate
element has
perforations in predefined first areas and in predefined dimensions, each
perforated area
providing a plurality of perforations, each perforation being made so as to
extend from the
first face to the second face, said perforations being filled with a polymer
with latent
energy recovery capability, wherein the polymer comprises a sulfonated block
copolymer
that has a water vapor transmission rate suitable for use in a total energy
recovery
ventilator (ERV).
The invention is also directed to a method for the production of an energy
recovery
ventilator, or ERV, that is defined by a plurality of heat exchanger elements
comprising:
a) producing a plurality of plate elements, each plate element having defined
outer
dimensions and corrugations in the area within a border that extends
completely
around the area containing the corrugations, wherein the plate element is made
from a material having sensible energy recovery capability, wherein the entire
border is free of corrugations and defines free edges of the plate element;
b) perforating the plate in predefined areas within the border and in
predefined
dimensions and locations, wherein said perforated area provides a plurality of
holes;
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c) filling the perforations with a polymer with high latent energy recovery
capability,
the filling being performed while the polymer is in a dissolved state and by a
technique that results in the polymer being directed into the perforations,
wherein
said plurality of holes when filled with the polymer allows the water vapor to
migrate
from one side of the plate material to the other side;
d) curing the polymer onto the plate for forming a polymer layer within the
perforations; and
e) combining the plurality of plate elements in stack form to define the
energy
recovery ventilator that is configured for residential and commercial
applications to
receive both exhaust air and incoming air, wherein the plurality of plate
elements
are constructed to act upon both the exhaust air and the incoming air by heat
and
moisture exchange therebetween.
The invention is also directed to a method for the production of heat
exchanger
elements comprising:
a) identifying environmental conditions in which the heat exchanger elements
are
to be placed for use;
b) producing a plate element that is made from a material having sensible
energy
recovery capability;
c) selectively perforating the plate in predefined areas and in predefined
dimensions, wherein said perforated area is selected based upon the
environmental conditions and provides a plurality of holes allowing the water
vapor
to migrate from one side of the plate material to the other, wherein the
plurality of
holes are arranged in a first pattern for use in first environmental
conditions and
are arranged in a second pattern for use in second environmental conditions
different than the first environmental conditions, the first pattern being
different
than the second pattern;
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d) individually filling the perforations with a polymer with latent energy
recovery
capability characterized by high water vapor transmission rate, the filling
being
performed while the polymer is in a dissolved state, wherein the polymer
comprises
a sulfonated block copolymer; and
e) curing the polymer so as to form a plurality of discrete polymer micro
membranes located within corresponding perforations of the plate elements;
wherein the heat exchanger element is configured for placement in an energy
recovery ventilator (ERV) and is constructed to act upon both incoming air and
exhaust air, by heat and moisture exchange therebetween, depending upon
environmental conditions.
According to the invention, a new hybrid exchanger element is provided which
on one
hand has enough structural strength and density to create air flow channels
for any type
of cross flow and/or counter flow energy exchanger, thereby allowing for the
use of a
structurally strong material which is good for sensible energy exchange, on
the other hand
by size and number of perforations or openings or holes it is possible to
define an area
which is filled with a polymer solution with latent energy exchange
characteristics. It is
obvious that the efficiency of sensible energy exchange on one hand and latent
energy
exchange on the other hand can be defined, controlled and adapted to the
respective
needs of the environment (dry air, humidity, outside temperature and the
like).
According to the invention, a plate element can be made of aluminium or
plastic or
combinations thereof. The element can be provided with corrugations.
Corrugations can
be designed to optimize the efficiency to pressure drop ratio. The
corrugations can be
chosen to allow for creating flow channels between similar plates when those
are stacked
together. By the definition of the corrugation, one advantage will be the
enhancement of
the surface which is available for energy transfer. This can be built up as
large as possible
and can even reach an increase of 100% and more. Furthermore, the corrugations
can
be designed in a way to allow for the easy arrangement of counter flow or
cross flow
configurations, e. g. by choosing oriented corrugations and alternating the
position of the
plate.
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The border of the plate defines an area where similar plates can be fixed
together in an
appropriate way. This can be welding, e. g. laser welding, ultra sound welding
and/or
folding, crimping and the like. This stabilizes the rigidity of the package as
well as allows
to build up the desired flow channels. The border area can be flattened,
tongue/groove
system, profiled or rimmed to allow for a tight sealable connection between
plates.
The perforations can be performed at the time of the plate production e. g.
integrally when
the plate is molded or stamped or embossed or vacuum formed.
The polymer can be one according to the state of the art, e. g. like the
product
"AquivionTm", a trademark of Solvay or "NexarTm", a trademark of Kraton.
The material can be e. g. a ionomer in form of a copolymer produced from
tetrafluoroethylene, C2F4, and ethanesulfonyl fluoride, 1,1,2,2-tetrafluoro-2-
[(trifluoroetheny1)-oxy], C2F3-0-(CF2)2-S02F, sulfonated block copolymer.
However, the polymers can be adapted to the desired characteristic and
features.
According to the inventions, the polymer is supplied as a dispersion. The
dispersion can
be brought to the plate by thereby filling or covering the holes or
perforations with the
polymer solution by way of spray, dipping, serigraphy or any other lamination
method. It
is obvious that the amount or efficiency of latent energy recovery depends on
the surface
provided by the holes or perforations, their shapes and their locations. So it
is possible to
adapt the heat exchanger plates to the environmental and functional
conditions.
By using the highly heat conductive materials as the structural elements for
the Enthalpy
membrane, high sensible efficiency is ensured. By defining the perforations
and choosing
the polymer, high latent recovery is ensured.
The corrugation/embossing of the plate increases the exchange surface
significantly.
The perforated or opened portions of each plate can reach 70% or more, of the
total
surface area e.g mosquito screen pattern. In such a case, the surface exceeds
that of a
flat membrane according to the state of the art), with minimal loss of the
high sensible
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energy recovery characteristic of the exchanger plates. A Total Energy
recovery efficiency
of up to 85% can be reached in heating mode and 72% in cooling mode. A number
of
finalized plates can be stacked together to build a package which, within a
frame or
housing, creates a heat exchanger according to the invention.
Combined sensible and latent energy to such a high Total Energy recovery level
could,
in some climatic zones, eliminate the need for a sensible only heat exchanger.
The polymer can be combined with additives to manifold and magnify its
attributes. It can
be, for instance, efficiently anti-bacterial and can meet fire resistance
requirements (UL).
Its viscosity can be adjusted to achieve the optimal tunable exchange features
of the plate
allowing as high a moisture exchange as possible.
It is obvious that the sensible energy transfer and the latent energy transfer
capabilities
of the heat exchanger are tunable and adjustable. The plates are adaptable to
environmental conditions by the variable mosaic geometry of the perforations.
E. g. an
exchanger can be designed to operate at temperature under the freezing point (-
10 C)
without ice built up only by choosing the right position of the perforations
and polymeric
treatment of the constitutive plates.
The rigidity of the structural elements could make the plate and thereby the
membrane
capable of handling pressure differential up to 1 Kpa. within the exchanger.
This
advantage opens the door to larger exchanger constructions for commercial
applications.
The invention provides a simple method for the production of energy exchanger
plates
allowing sensible as well as latent energy exchange. The design and the
adaptability of
the plates allows for the construction and design of heat exchangers which are
optimized
with regard to the technical requirements and/or the environmental conditions.
Stamped, corrugated, embossed or vacuum formed aluminium, stainless steel,
resin
based plates and/or plastic plates can be made using proven automation
technologies
including the assembly, e. g. by vacuum grip, and seal, e. g. by laser
welding, ultra sound
welding, folding, crimping, to obtain packages of superposed rigid plates. The
plates are
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washable, fire resistant, antibacterial, sealed e.g. leakage proof. They have
all valuable
advantages that are necessary to create highly efficient heat exchangers.
The selective perforation of the plates and the air-tight casting of the
mosaic polymer
micro membranes allows for the construction of structural hybrid mosaic
membranes. The
plate perforation, too, can be performed by pre-programmed continuous laser
processes,
by mechanical systems like needle-roller and the like, or chemical etching
processes.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and aspects of the invention become obvious from the
following
description of the drawings. The drawings show:
Fig. 1 a top view of one example for an embodiment of an exchanger plate
according to the invention; and
Fig. 2 a side view of the plate according to figure 1.
DESCRIPTION OF EMBODIMENTS
In the drawings, the same elements are designated by the same reference
numbers.
An exchanger plate 1 consists of a structural rigid plate 2 made from
aluminium, plastic
or the like. Plate 2 has a rim 4 which is a flat sealable rim and can be
deformed for sealing.
Areas of the rim 4 are opened or deviated as shown by reference no. 5 to
define e. g. a
inlet and outlet of a flow channel. Within the rim area, corrugations 3 are
stamped or
embossed into the plate 2. When similar plates are sealed together, flow
channels are
defined. In the example, reference no. 6 designates areas with perforations.
For the purpose of clarity, only some of the perforation areas 6 and some of
the
corrugated areas 3 are designated.
The heat exchanger element 1 shows a great surface for heat exchange which is
increased by the corrugations 3 which are corrugated in one direction only and
open on
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the other surface. Furthermore, the perforated areas 6 define a latent energy
exchange
area for the transfer of moisture.
These plates will be stacked to build a heat exchanger e. g. for ventilation
systems to
exchange heat from outgoing to incoming air (or vice versa for free cooling in
summer)
as well as humidity from outgoing to incoming air in winter (or vice versa for
moisture
reduction in summer or all year round in hot and humid climatic zones).
The drawings and the description do in no way restrict the invention and are
meant for
describing an example, only.
Reference numerals:
1 heat exchanger element
2 plate
3 corrugation
4 border
5 opened border
6 perforations.
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